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Energy Efficiency Allround

Think holistically – save energy

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In a region valued for its natural beauty which welcomes many holidaymakers annually, ARBURG adopts a far-sighted approach

and takes its corporate responsibilities seriously. ARBURG protects the vulnerable environment through its work with and within a state-

of-the-art technical infrastructure. ARBURG makes use of the necessary resources whilst also protecting nature and the environment through the

most energy-efficient production and management possible. In other words, ARBURG is a company that operates in harmony with the environment. Through the generations, the Hehl founding families have always had a keen awareness of these relationships. Responsibility with regard to social aspects as well as environmental and energy policy is the central benchmark within ARBURG’s corporate culture.

“Being a trendsetter, working energy-efficiently”

Partners Michael Hehl, Renate Keinath and Juliane Hehl: “Our families have always been interested

in energy efficiency.”

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Energy optimisation: a holistic viewExpansion, exterior design, energy mana­gement, building services management and innovative production techniques on the one hand; modular, energy­optimised products and comprehensive, consistent customer advice about energy matters on the other: for ARBURG to be able to work energy-efficiently on a sustainable basis, both aspects of our corporate culture must interact holistically. And all this goes hand in hand with the protection and prudent use of limited natural resources. For this reason, ARBURG has been working on the basis of combined quality and environmen­tal management standards 9001 and ISO 14001 since 1996. Furthermore, since 2012, certification to ISO 50001 commits ARBURG to the efficient use of energy in all areas of the company.

“Energy Efficiency Allround” incorporates all measuresThe all­embracing initiative entitled “Energy Efficiency Allround” is a long-term approach extending far beyond corporate and production-based measures. ARBURG also sees the ALLROUNDER machine range in terms of energy efficiency, and provides its customers with innovative, energy­ optimised injection moulding technology. In this way, the company also contributes to customers’ efforts towards energy efficiency. And ARBURG’s endeavours are backed up impressively by the assignment of the “e2” Energy Efficiency Label to all energy­optimised ALLROUNDERs since 2008, and by the information it provides to interested customers around the world on energy­saving possibilities in the technical injection moulding process.

Introduction

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The declared goal of the company-wide energy-saving activities put into practice at ARBURG is to optimise the energy consumption of production systems and buildings. Therefore, as the first step, actual consumption is continuously recorded, monitored and evaluated with the aim of finally obtaining meaningful key figures and energy flows. Initially, it is necessary to reduce the amount of energy required - by the comprehensive use of energy-saving bulbs and frequency-controlled ventilation motors, for example. In addition, use can be made of naturally avail able resources, such as the sun’s rays. Finally, the efficiency of our energy usage can also be increased by improving heat insulation, for example, or reducing flow resistance.

Building services management: efficient energy use as a corporate responsibility

Taking nature as an example: using sunshine, shade

and outside air to achieve the right climate.

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Anchoring energy savings in our strategyGiving all energy­saving measures a longer term strategic focus ensures that the ex­pected energy requirements of new sys­tems and/or building extensions are already taken into consideration during the plan­ning stage. One of ARBURG’s important goals in the planning and renovation of building extensions is to achieve the most energy-optimised construction possible. Key words here are heat insulation, for example, and natural climate control by means of sunlight, shade and outside air. To this aim, we use advanced wall­constructions and glazing.

Low­temperature façade heating provides the necessary heating for large areas of the building. Where the provision of heat is concerned, only the basic load is supplied by energy-efficient block-type thermal pow­er plants. Compressed air is conditioned in a decentralised manner via several condi­tioning units. Energy consumption for light­ing is kept to a minimum by switching sys­tems with motion sensors and twilight switches. Of course, the perfect function of all business processes is also given full con­sideration in construction planning..

Building services management

Optimum insulation: double glazing utilizes the full daylight and the resulting

warmth of the sun.

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Using renewable energyThe buildings are designed to enable the use of renewable energy wherever feasible. For example, ARBURG makes use of the orientation of its production halls and the angle of inclination of the saw­toothed roofs for the installation of solar collectors. In total an area of 1,600 square metres has been covered with solar collectors, which

have an output capable of supplying around 100 households a year with environmentally friendly electricity.

Geothermal bore holes beneath the new Customer Center contribute to the opti­mum harvesting of available heat potential. For example, this system can store recov­ered waste heat in the earth in a dual­ action process and “retrieve” it when required. All in all, 24 bore holes each 199 metres deep have been drilled. This type of energy harvesting enables ARBURG to gain some 600,000 kilowatt­hours of heating capacity and around 400,000 kilowatt­hours of cooling capacity per year.

Building services management: efficient energy use as a corporate responsibility

Block-type thermal power plant: highly efficient use of primary energy

through combined heat and power generation - in this case with gas.

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Building services management

Using regulated motors and drivesTo optimise consumption and suppress en­ergy peaks, ARBURG insists on using regu­lated motors and drives. Energy-saving mo­tors of efficiency class EFF1 are installed whenever new or replacement motors are required. The multi-stage or stepless control of motors and drives ensures that energy consumption is adapted in line with the re­quired output. But regulated drives are also employed in all ALLROUNDERs. These work according to demand on the one hand, and collect waste heat in their water cool­ing system and pass it on for further use on the other hand. This is the case for both hydraulic machines and electric ALLROUNDER A machines.

In this way, state­of­the­art injection moulding machines can be comprehensively used for energy-efficient part production in injection moulding plants.

Deep drilling: with geothermal energy, ARBURG stores heating and cooling

energy in the ground.

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Even now, in this age of globalisation, ARBURG produces its machine technology at its central headquarters in Germany. Accordingly, the company motto is “Made by ARBURG - Made in Germany”. In order to be able to produce cost-effec-tively and at competitive prices despite its location in a classic “high-tech country” - with all the advantages and disadvantages this entails - ARBURG continually strives to modernise and further develop its production processes. To bring about this optimisation, production equipment, production planning and part design all have to interact in very close harmony. This holistic view must be put into practice by minimising material input, processing time, production steps, machine down-times and rejects. To achieve this, it is necessary to examine the entire value-added chain of production. As a pioneer and innovative force in injection moulding ma-chine construction, ARBURG incorporates these basic principles in the continuous optimisation of production. And the direct beneficiaries are all our customers.

Production technology: innovative production processes use energy more efficiently

Qualified employees think and act energy-efficiently.

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Using innovative production methodsWhere surface finishing is concerned, for example, energy is saved not just through new, improved processing methods and the use of new machine and system technology, but also by employing innovative consuma­bles. As long ago as 1994, we were able to balance economical and ecological require­ments in the long term by discontinuing salt bath nitriding and introducing plasma nitrid­ing in ARBURG production. Not only is this hardening process more eco­friendly and energy efficient - parts treated using this method also have considerably improved corrosion protection. Moreover, this tech­nique dispenses with cost­intensive grinding and other finishing work.

With ARNOX, an improved treatment for tie bars that further enhances cor rosion protection has been introduced. The ARBURG no­oxidation process is an innovative method of treating tie bars, which also increases fatigue strength and therefore vastly reduces tie bar distortion. All tie bars that are mounted on ALLROUNDER injection and clamping units are now produced using this special technique. This results in a classic win- win situation both for customers and for ARBURG: customers benefit through high-quality materials, ARBURG through the use of a cost-effective, energy-efficient and en­vironmentally friendly production process.

Production technology

Plasma nitriding: a modern hardening technique

for fewer processing steps.

Powder coating: making better use of material and

simultaneously protecting the environment.

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Reducing material input, shortening processing timesBy dispensing with unnecessary machining work by prefabricating raw materials with the most precise contours possible instead of using conventional solid blanks, ARBURG achieves high efficiency in terms of material costs on the one hand, and shorter process­ing times on the other hand. This allows energy to be saved in several ways at once.Cast and forged parts, which are finished at ARBURG, are prefabricated in such a way that only minimal further processing is nec­essary to provide them with their final shape. In other words, close co-operation between Design and Production ensures that the cast parts and their final geometry are already closely matched from the start. The use of special processes such as friction welding also helps to reduce energy­inten­sive machining work. This innovative metal­

Production technology: innovative production processes use energy more efficiently

Friction welding: greatly reducing energy-intensive machining work.Saving time and costs: prefabrication with precise contours means less

metal casting work.

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bonding process using rotation and pres­sure enables different geometries and ma­terials to be combined in a positive material bond.

Targeted minimisation of production stepsBy continuously working on develo p­ ment and model refinement, it is often possible to make use of sheet metal con­structions instead of solid blanks on all ALLROUNDERs. Substitution and reduction are important concepts for energy-efficient sheet metal processing. ARBURG regards its primary goal as saving energy through the optimised design of light sheet metal con­structions, which replace solid blanks, while achieving the same quality standard. Here, energy efficiency is achieved on the one hand by the use of state­of­the­art machine technology, which combines several work

steps, and on the other hand by the con­sistent implementation of techniques that help to reduce the number of materials and parts and therefore save costs and ­ last but not least - energy. In sheet metal process­ing, complex bent or deep­drawn parts such as machine bases and control cabinet doors, for example, are achieved using modern sheet metal forming machines, also in combination with automatic welding systems. Another energy-saving technique is concealed tack welding, used in place of seam welding. In this way, by optimising sheet metal plates, stacking and minimising scrap, production steps can be reduced and, as a consequence, material and energy costs lowered.

In focus: replacing solid blanks with sheet metal

constructions.

Production technology

Modern sheet metal processing: combining production processes

to optimise energy use.

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Optimum production planningFirst and foremost, efficient production planning is aimed at reducing machine downtime while simultaneously maximising machine running times and avoiding re­jects. For all these factors result in energy wastage. Using the following methods, ARBURG ensures optimum exploitation of machine capacity and constantly high quality:

Production technology: innovative production processes use energy more efficiently

Intelligent production: order data available online

at all times.

Always in view: due maintenance work on

production systems.

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• Central control systems, the use of optimised transport for example. Empty trips are avoided and energy is saved.

• Comprehensive maintenance manage­ment. Machines and drives are regularly monitored and serviced via central maintenance software.

• All­embracing quality management on the basis of ISO 9000 certification.

Once again, it is clear that ARBURG’s thoughts and actions are consistently at­tuned to the advantage of its customers: in addition to our own endeavours to con­tinuously optimise production, the ARBURG product range also includes production optimisation tools, such as the ARBURG host computer system (ALS) and ARBURG Quality Control (AQC).

Comprehensive quality management: consistently

avoiding rejects.

Production technology

Optimising the material flow: all components automatically in the right

place just in time.

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Even now, industry lends far too little consideration to heat recovery in production and offices with the aim of energy-efficient working. On the one hand, large buildings require a great deal of heat; on the other hand, a great deal of waste heat is generated by energy-intensive production processes. However, exploiting this very situation - which can only be changed with difficulty - by means of a so-lution-oriented approach opens up possibilities for integrated energy supply con-cepts and combined process heat management. At ARBURG, waste heat generated by production processes is effectively utilised, recovered and conveyed to the vari-ous heating circuits.

Heat recovery: recycling energy

Putting waste heat to good use: ALLROUNDERs

heat buildings in test runs.

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Putting waste heat to good useIn order to use energy several times over, the centralised process heat management system practised in all areas of the ARBURG company makes use of state­of­the­art recovery technology. Thanks to this target-oriented approach, ARBURG has already been able to save considerable quantities of primary energy and therefore also pre­empt rising energy costs. For many years now, ARBURG has been continually improv­ing and promoting the use of waste heat, which is produced not just during commis­sioning, test runs and process testing of ALLROUNDERs, but also during the genera­

tion of compressed air and electricity by block-type thermal power plants. The heat energy collected throughout the company is used for all the low­temperature under­floor heating and for heating the façade of the office building, for example. Moreover, it is used for preheating and drying in pro­duction systems such as powder coating, for instance. But this kind of integrated approach enables investment costs to be saved in other areas, too. The office build­ing does not need any radiators, for exam­ple. The heating fluid simply flows through the floor and the façade.

Heat recovery

Temperature-regulated office building: the façade is heated entirely using waste heat.

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Cooling with waterWaste heat from exhaust air from the pro­duction halls is put to use by means of air/air heat exchangers and “heat recovery wheels”, or “Econovent”, systems. The waste heat in the air is therefore reused. But the waste heat in the cooling water conveyed out of production systems can also be reused and transported to a defined location, stored in the ground using geo­thermal technology, for example, and then recovered. This is why at ARBURG, units such as compressors, chillers and hydraulic systems are always water-cooled.

Heat recovery: recycling energy

Waste heat is used twice: Econovent system in production.

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PlatzhalterWärmerückgewinnung

Heat exchangers and heat pumps are used for this purpose. This way of thinking is reflected in our products, too: for the ALLROUNDERs, control cabinets, hydraulic units and servo motors are also water­cooled. Consequently, all ARBURG custom­ers have the opportunity to put waste heat to effective use and work with greater en­ergy efficiency. Our ARBURG specialists provide individual advice on the best way to achieve this.

94 % of waste heat produced during compressed

air generation is reused.

Heat recovery

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In order for a high-tech company such as ARBURG to be sure of optimum energy consumption, solution concepts are required that ensure a constant climate over an area of around 146,000 square metres. This is why we have been making use of central building services management for our entire process management for over 20 years. This management instrument organises the company’s high energy re-quirements in the form of an integrated energy supply concept that is applied throughout the company.

Process management: integrated overall concept for energy consumption

Skylights in saw­toothed roofs, moved by an invisible

hand: automatic ventilation is economical.

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Central management of energy useCentral building services management (BSM) weaves together the various threads of energy use and climate control at ARBURG. Here, all processes are recorded and regulated, either automatically or by operating personnel. Obvious examples are skylights in saw­toothed roofs and blinds, which move automatically depend­ing on the data from the company’s own weather station, or the lighting in the pro­duction halls, which switches itself on and off depending on the intensity of the day­light. Ventilation is primarily achieved using regulated drives. This in turn enables the BSM system to distribute energy loads in such a way as to avoid energy peaks.

Energy costs can be nipped in the bud through intelligent peak-load optimisation. To this aim, ventilation units are switched off or the speed of regulated motors re­duced. Ventilation and air-conditioning systems are generally stationary at week­ends and on non-working days. At night, the cool night air is used to ventilate pro­duction and office buildings by means of so-called “summer night ventilation”. During the daytime, the opening of win­dows and ventilation control are connected: if windows are opened, the ventilation au­tomatically switches itself off. Control of the air conditioning by the BSM system reliably prevents heat conduction in sum­mer and heat loss in winter.

Process management

Fully networked: building automation via centralised control systems.

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Demand-based indoor climate controlAn integral and also extremely energy-effi­cient aspect of this process management is the low-temperature cascade connection. To save energy, this ensures that the re­quired heating media are heated only as much as is necessary for their use in the various areas of the company. So not only are heating, ventilation and cooling contin­uously monitored, they are also constantly being adapted in line with the prevailing conditions.

Process management: integrated overall concept for energy consumption

Put to effective use: lighting controlled by light

sensors.

Control wherever it’s needed: lighting is monitoring and regulated by the

central building services management (BSM) system.

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Fully networked building services managementThe building services management (BSM) system ensures that machines throughout the company are working perfectly, com­munications are functioning and the cli­mate is just right. The entire infrastructure, such as the block­type thermal power plant, refrigeration systems, machining centres, the air conditioning and, finally, the fire pre­vention system, is networked. In order to create the best possible conditions for

energy­saving temperature control and air conditioning, extensive sensor connections are used throughout the company to continuously determine outside and room temperatures. Freely programmable control systems connect the complete building ser­vices management system to the BSM’s central computers, which execute all control commands immediately and report warn­ings and alarms back to the control centre.

Weather-dependent: ventilation depends on data from the company’s

own weather station.

Process management

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The basic philosophy for achieving energy efficiency at ARBURG is based to a great extent on holistic thought and action. For ARBURG, there is no longer a difference between production and the product. For this reason, the strategies that we pur-sue in the areas “Energy efficiency in the company” and “Energy-efficient prod-ucts” are not different, but two sides of the same coin. Whether we’re talking about production and management or ALLROUNDER injection moulding machines, both the company and the products are governed by the same principles and guidelines. Both must work as energy-efficiently as possible. For in the end, this also explains why the company continues to produce centrally and very success-fully at its site in Germany.

“Holistic thinking for Energy Efficiency Allround”

Energy Efficiency Allround: here, too,

ARBURG is a competent consulting partner.

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Innovations deliver greater energy efficiencyARBURG ensures greater energy efficiency through the entire value-added chain. This is achieved on the one hand by energy-effi­cient production by ARBURG machine tech­nology that is sold world­wide, with mod­ern, energy­saving production facilities and buildings. On the other hand, however, ARBURG’s groundbreaking and also energy­efficient products ensure optimised energy use by its customers, too. An excellent example of this is the electric ALLROUNDER A. These modular machines are designed for the comprehensive use of energy-efficient drives on all movement axes for a wide range of applications in the plastics processing industry.

Advice that extends far beyond machine technologyThese innovative products are comple­mented by wide­ranging training and infor­mation activities highlighting possible ways of efficiently reducing energy requirements, irrespective of the machine technology in use. Furthermore, all customers can make use not only of ARBURG’s extensive process expertise, but also of assistance in planning their entire injection moulding production. Here, too, ARBURG is a competent consult­ing partner, that uses its own extensive know­how to give its customers that extra help. For only holistic, strategic planning and implementation can help to create a truly energy-efficient injection moulding operation.

Summary

Resource­saving action: for Managing Partners

Eugen (on right) and Karl Hehl (1923­2010),

always a central component of company strategy.

Synonymous with energy-efficient injection moulding technology:

Made by ARBURG - Made in Germany.

ARBURG GmbH + Co KG

Postfach 11 09 · 72286 Lossburg · Tel.: +49(0)7446 33-0 · Fax: +49(0)7446 33-3365 · www.arburg.com · e-mail: contact@arburg.com

With locations in Europe: Germany, Belgium, Denmark, France, United Kingdom, Italy, Netherlands, Austria, Poland, Switzerland, Slovakia,

Spain, Czech Republic, Turkey, Hungary | Asia: People’s Republic of China, Indonesia, Malaysia, Singapore, Thailand, United Arab Emirates | America: Brazil, Mexico, USA

For more information, please go to www.arburg.com.

ARBURG GmbH + Co KG Quality

DIN EN ISO 9001 + 14001 + 50001 certified 6802

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© 2015 ARBURG GmbH + Co KGThe brochure is protected by copyright. Any utilisation, which is not expressly permitted under copyright legislation, requires the previous approval of ARBURG.